FORM 2
THE PATENTS ACT 1970
[39 OF 1970]
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
[See Section 10 and Rule 13]
TITLE: “A FRONT SUSPENSION SYSTEM OF A VEHICLE”
Name and address of the Applicant:
TATA MOTORS LIMITED; Bombay House, 24 Homi Mody Street, Hutatma Chowk, Mumbai 400 001 Maharashtra, India
Nationality: Indian
The following specification describes the nature of invention and the manner in which it is to be performed.

TECHNICAL FIELD
Present disclosure in general relates to the field of automobile engineering. Particularly but not exclusively, the present disclosure relates to a suspension system with the frame of a vehicle. Further, embodiments of the disclosure disclose a front suspension system of the vehicle.
BACKGROUND OF THE DISCLOSURE
Vehicles are a universal form of travel and transport. Generally, vehicles include suspension systems to absorb undue vibrations due to contact of wheels on undulations arising from surfaces of the road, thereby providing a comfortable commuting experience. Suspension systems come in various forms and requirements based on the application use of the vehicle. As an example, light utility vehicles like cars, are equipped with softer suspension to provide effective traction of the wheels and comfort to the passengers. Heavy transport vehicles such as pick-up trucks, semi-trucks, and tipper trucks are conventionally used to carry heavier loads and are equipped with a stiffer suspension system.
Various types of suspension systems are mounted to the vehicle, based on the configuration and requirement. One such configuration of the suspension systems is the pneumatic suspension system which uses bellows to absorb vibrations and forces generated during movement of the vehicle. In conventional pneumatic suspension systems suitable for medium floor height (≤900 mm) vehicles, bellows are mounted outside of long members to meet floor height requirements. Such configuration requires offset and overhanging mounting arrangement both on the axle and frame side, leading to an increase in weight and cost. Further, the conventional pneumatic suspension systems include a double drop axle, which increases the weight and cost of the pneumatic suspension system, which is undesired. Furthermore, the conventional pneumatic suspension systems include a V-type torque rod arrangement with an anti-roll bar. This arrangement leads to packaging constraints as the V-type torque rod arrangement occupies a larger space in front of the axle. Also, the V-type torque rod arrangement causes hindrance during servicing as it blocks access to several subsidiary components.
The present disclosure is directed to overcome one or more limitations stated above and any other limitations associated with the prior arts.

SUMMARY OF THE DISCLOSURE
One or more shortcomings of the conventional system are overcome, and additional advantages are provided through the provision of the front suspension system as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
In one non-limiting embodiment of the disclosure, a front suspension system of a vehicle is disclosed. The suspension system includes a bellow defined with a first end and a second end. The first end is coupled to the bottom portion of each of a pair of long members of the vehicle, and the second end is coupled to a saddle supported on an axle. Further, the suspension system includes a support bracket coupled to a portion of each of the pair of long members and positioned at a distance from the bellow. Furthermore, the suspension system includes a stabilizer link extending between the bracket and the saddle, and a torque rod extending parallel to the stabilizer link and between the support bracket and the saddle. Additionally, the front suspension system includes a cross-member extending between the pair of long members, and coupled to the portion of the pair of long members and the first end of the bellow.
In an embodiment of the disclosure, each of the pair of long members is defined with a constant or variable relatively, smaller or same section with respect to the central portion for packaging of bellow of the front suspension system.
In an embodiment of the disclosure, the axle is a single drop axle.
In an embodiment of the disclosure, the stabilizer link is structured to support the ends of an anti-roll bar.
In an embodiment of the disclosure, the first end of the bellow is coupled to the bottom portion of each of the pair of long members through a support structure.
In an embodiment of the disclosure, the cross-member comprises one or more structural members, each of the one or more structural members removably securable to each other and extending in a width direction of the vehicle. Further, the cross-member includes a plurality of connecting flanges removably secured to one or more structural members at

pre-defined positions and orientations. The plurality of connecting flanges is configured to connect one or more structural members to portions of the pair of long members.
In an embodiment of the disclosure, each of the plurality of connecting flanges is defined with a plurality of mounting apertures. The plurality of mounting apertures is configured to receive fastening elements adapted to secure the plurality of connecting flanges to the portion of the pair of long members.
In an embodiment of the disclosure, the cross-section of each of the one or more structural members includes one of a trapezoidal and a dog-bone shape.
In another non-limiting embodiment of the disclosure, a vehicle is disclosed. The vehicle includes a pair of long members extending in a vehicle-length direction. Further, the vehicle includes a front suspension system coupled to each of the pair of long members. The front suspension system includes a bellow defined with a first end and a second end. The first end is coupled to the bottom portion of each of a pair of long members of the vehicle, and the second end is coupled to a saddle supported on an axle. Further, the suspension system includes a support bracket coupled to a portion of each of the pair of long members and positioned at a distance from the bellow. Furthermore, the suspension system includes a stabilizer link extending between the bracket and the saddle and a torque rod extending parallel to the stabilizer link and between the support bracket and the saddle. Additionally, the front suspension system includes a cross-member extending between the pair of long members and coupled to the portion of the pair of long members and the first end of the bellow.
It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:
Figure. 1 illustrates a perspective view of a front suspension system with frame for a medium floor height vehicle (≤ 900 mm), in accordance with an embodiment of the present disclosure.
Figure. 2 illustrates a perspective view of the front suspension system for the vehicle of Figure. 1, without depicting a pair of long members.
Figure. 3 illustrates a top view of the front suspension system of Figure. 1.
Figure. 4 illustrates a side view of the front suspension system of Figure. 1.
Figure. 5 illustrates a schematic view of a long member, in accordance with an embodiment of the present disclosure.
Figure. 6 illustrates a perspective of a cross-member of the front suspension system, in accordance with an embodiment of the present disclosure.
The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
While the embodiments in the disclosure are subject to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular form disclosed, but on the contrary, the

disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
It is to be noted that a person skilled in the art would be motivated by the present disclosure and modify various constructions of the front suspension system, which may vary from vehicle to vehicle. However, such modifications should be construed within the scope of the disclosure. Accordingly, the drawings show only those specific details that are pertinent to understand the embodiments of the present disclosure, so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such assembly. In other words, one or more elements in the assembly proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the assembly.
The following paragraphs describe the present disclosure with reference to Figures. 1 to 6. In the Figures, the same element or elements that have similar functions are indicated by the same reference signs. In the figures, the vehicle is not illustrated for the purpose of simplicity.
Figure. 1, illustrates a perspective view of a front suspension system (100) for a vehicle. The front suspension system (100) may be adopted in vehicles having different floor heights, without the need of modification. As an example, the vehicle can be of at least several different uses and can be referred to as a heavy and light-duty vehicle including but not limited to a work vehicle, a bus, a material hauling vehicle, a fire-fighting vehicle, caravan, and the like. Also, the vehicle may include sports utility vehicles (SUVs), multi-utility vehicles (MUVs), pick-up trucks, and the like without deviating from the scope of the present disclosure. The front suspension system (100) may include a bellow (105) which may be defined with a first end (106) and a second end (107) [as seen in Figure. 2], which may be opposite to the first end (106). The first end (106) of the bellow (105) may be coupled to a bottom portion (104) of each of a pair of long members (101) of the

vehicle and the second end (107) may be coupled to a saddle (117) supported on an axle (111). As an example, the axle (111) may be a single drop axle. In an embodiment, the first end (106) of the bellow (105) is coupled to the bottom portion (104) of each of the pair of long members (101) through a support structure (116). In an embodiment, each of the pair of long members (101) may extend in a length direction of the vehicle. That is each of the pair of long members (101) may extend in a vehicle front-rear/back direction. In an embodiment, the pair of long members (101) may be spaced apart from each other and may be provided to have a pre-determined distance therebetween in a traverse or width direction of the vehicle. Each of the pair of long members (101) may extend substantially parallel to each other from a front end to a rear end of the vehicle. The pre-determined distance between the pair of long members (101) may vary based on the type of vehicle, thus the specific dimensions are not illustrated in the present disclosure. As apparent from Figure. 5, each of the pair of long members (101) may be defined with a constant or variable relatively, smaller or same section (103) with respect to central portion (102) for packaging of bellow (105) of front suspension system (100). The configuration of the long members (101) aids in providing necessary reinforcement to the front suspension system (100). Further, as the bellows (105) are positioned below the long members (101) and the axle (111), the single drop axle (111) may be used, which is lesser in weight, when compared to conventional high/ double drop axle which are costly and has increased weight. Further, positioning the bellows (105) below the axle (111) eliminates the need of complex mounting arrangement, thereby reducing cost and weight. Use of relative bigger section central portion (102) in long members (101) helps to meet strength requirement without much weight addition for structural rigidity.
Referring further to Figure. 1 in tandem with Figures. 2 to 4, the front suspension system (100) may include a support bracket (108) which may be coupled to a portion of each of the pair of long members (101) and positioned at a distance from the bellow (105). The support bracket (108) may be coupled to the portion of the each of the long members (101) through one of a mechanical joining process and a thermal joining process. Further, the front suspension system (100) may include a stabilizer link (109) which extends between the support bracket (108) and the saddle (117), and a torque rod (110) which extends parallel to the stabilizer link (109) and between the support bracket (108) and the saddle (117). The stabilizer link (109) and the torque rod (110) supports the axle (111), i.e., supports the axle (111) in relation to the pair of long members (101). In

an embodiment, the stabilizer link (109) may be configured to support ends of an anti-roll bar (118). This configuration of the stabilizer link (109) and the torque rod (110) aids in packaging of a prime mover ahead of the axle (111). This configuration aids in easy servicing and assembling as there is no interference of subsidiary components, unlike conventional arts which used a V-type rod arrangement with the anti-roll bar, which needs removal of V type rods prior to assembly or service. Further with this arrangement placement of any subsidiary components in between torque rod (110) & stabilizer link (109) is possible which is otherwise not possible with V type torque rod arrangement as it will to interfere/ foul during articulation, due to wheel movement.
Referring back to Figure. 1, the front suspension system (100) may include a cross-member (112), which extends between the pair of long members (101) and coupled to the portion of the pair of long member and the first end (106) of the bellow (105). As apparent from Figure. 6, the cross-member (112) provides structural rigidity to the front suspension system (100). The cross-member (112) may include a one or more structural members (113). Each of the one or more structural members (113) may be removable secured to each other and may extend in a width direction of the vehicle. In an embodiment, the cross-section of each of the one or more structural members (113) include one of a trapezoidal and straight or dog-bone shape. The structural members (113) may be secured to each other by at least one of mechanical joining process and/or thermal joining process without deviating from the scope of the present disclosure. The mechanical joining process includes fastening, riveting and the like. The thermal joining process includes welding and the like. The type of joining process should not be construed as the limitation of the present disclosure. Further, the cross-member (112) may include a plurality of connecting flanges (114) which may be removably secured to the one or more structural members (113) at predefined positions and orientations. The plurality of connecting flanges (114) are configured to connect the one or more structural members (113) to portions of the pair of long members (101). In an embodiment, the plurality of connecting flanges (114) may be defined with a plurality of mounting apertures (115). The plurality of mounting apertures (115) may be configured to receive fastening elements adapted to secure plurality of connecting flanges (114) to the portions of the pair of long members (101).

In an embodiment, the cross-member (112) of the present disclosure may be modular as it can be modified/configured into wide range of sections with limited tooling, also has provision to modify the section to provide adequate stiffness, accommodate auxiliary components, and the like. Also, desired width may also be achievable by reconfiguring the components associated with the cross-member (112). Further, the one or more structural members (113) may be defined with a plurality of ribs (not explicitly shown] to improve the mechanical properties including rigidity of the one or more structural members (113).
The configuration of the cross-member (112) apart from providing structural rigidity to the front suspension system (100) aids sufficient clearance because of the profile i.e., trapezoidal and dog-bone shape, for a propeller shaft of the vehicle to extends toward rear wheels of the vehicle without interference.
Equivalents:
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and

indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims

Referral Numerals:

Referral numeral Description
100 Front suspension system
101 Long members
102 Central portion
103 Front portion
104 Bottom portion
105 Bellow
106 First end
107 Second end
108 Support bracket
109 Stabilizer link
110 Torque rod
111 Axle
112 Cross-member
113 Structural members
114 Connecting flanges
115 Mounting apertures
116 Support structure
117 Saddle
118 Anti-roll bar

We Claim:
1. A front suspension system (100) of a vehicle, the system (100) comprising:
a bellow (105) defined with a first end (106) and a second end (107), wherein the first end (106) is coupled to a bottom portion (104) of each of a pair of long members (101) of the vehicle, and the second end (107) is coupled to a saddle (117) supported on an axle (111);
a support bracket (108) coupled to a portion of each of the pair of long members (101), and positioned at a distance from the bellow (105);
a stabilizer link (109) extending between the support bracket (108) and the saddle (117);
a torque rod (110) extending parallel to the stabilizer link (109) and between the support bracket (108) and the saddle (117); and
a cross-member (112) extending between the pair of long members (101) and coupled to the portion of the pair of long members (101) and the first end (106) of the bellow (105).
2. The system (100) as claimed in claim 1, wherein each of the pair of long members (101) are defined as a constant or variable, relatively smaller or same section (103) with respect to central portion (102) for packaging of the bellow (105) of front suspension system (100).
3. The system (100) a claimed in claim 1, wherein the axle (111) is a single drop axle.
4. The system (100) as claimed in claim 1, wherein the stabilizer link (109) and the torque rod (110) supports the axle (111).
5. The system (100) as claimed in claim 1, wherein the stabilizer link (109) is structured to support ends of an anti-roll bar (118).
6. The system (100) as claimed in claim 1, wherein the first end (106) of the bellow (105) is coupled to the bottom portion (104) of each of the pair of long members (101) through a support structure (116).

7. The system (100) as claimed in claim 1, wherein the cross-member (112)
comprises:
one or more structural members (113), each of the one or more structural members (113) removably securable to each other and extending in a width direction of the vehicle;
a plurality of connecting flanges (114) removably secured to the one or more structural members (113) at pre-defined positions and orientation, the plurality of connecting flanges (114) is configured to connect the one or more structural members (113) to portions of the pair of long members (101).
8. The system (100) as claimed in claim 7, wherein each of the plurality of connecting flanges (114) is defined with a plurality of mounting apertures (115), the plurality of mounting apertures (115) is configured to receive fastening elements adapted to secure plurality of connecting flanges (114) to the pair of long members (101).
9. The system (100) as claimed in claim 7, wherein cross-section of each of the one or more structural members (113) includes one of a trapezoidal and a dog-bone shaped.
10. A vehicle comprising:
a pair of long members (101) extending in a vehicle length direction; and a front suspension system (100) coupled to each of the pair of long members (101), the front suspension system (100) comprising:
a bellow (105) defined with a first end (106) and a second end (107), wherein the first end (106) is coupled to a bottom portion (104) of each of the pair of long members (101) of the vehicle, and the second end (107) is coupled to a saddle (117) supported on an axle (111);
a support bracket (108) coupled to a portion of each of the pair of long members (101), and positioned at a distance from the bellow (105);
a stabilizer link (109) extending between the support bracket (108) and the saddle (117);
a torque rod (110) extending parallel to the stabilizer link (109) and between the support bracket (108) and the saddle (117); and

a cross-member (112) extending between the pair of long members (101) and coupled to the portion of the pair of long members (101) and the first end (106) of the bellow (105).